SILNIK 3,0 CRD 2011-

WYMIANA LEWEJ USZCZELKI GŁOWICY

1. Clean and inspect gasket mating surfaces 

 
1. Remove the  (1).

 
1. Set the number one piston to top dead center (TDC).
   
   
   

   NOTE:

   Typical view of scooter block.

 
1. Using the  (2) and the  (1), position the Scooter block with dial indicator flat on the cylinder block head surface and zero the dial indicator (1).
   
   
   
   

   NOTE:

   Typical view of scooter block.

 
1. Position the scooter block with dial indicator (1) onto the piston (2).
   
   

 
1. Measure the height of the piston in the location illustrated (1) and record measurement.

 
1. Measure the height of the piston in location illustrated (2) and record measurement.

 
1. Repeat the procedure for each cylinder.

 
1. Use the highest reading of the 4 piston protrusion readings to determine the required gasket thickness.
   
   

   HEAD GASKET SELECTION CHART
   	Metric	Standard
   PISTON CLEARANCE	0.130 - 0.220 mm	0.0051 - 0.0086 in.
   CYLINDER HEAD GASKET THICKNESS	0.96 mm	0.0377 in.
   GASKET IDENTIFICATION	NO HOLE
   PISTON CLEARANCE	0.221 - 0.310 mm	0.0087 - 0.0122 in.
   CYLINDER HEAD GASKET THICKNESS	1.06 mm	0.0417 in.
   GASKET IDENTIFICATION	ONE HOLE
   PISTON CLEARANCE	0.311 - 0.402 mm	0.0122 - 0.0158 in.
   CYLINDER HEAD GASKET THICKNESS	1.16 mm	0.0456 in.
   GASKET IDENTIFICATION	TWO HOLES

   
   
   
   

   NOTE:

   The above illustration shows gasket identification marks.

 
1. Select the appropriate cylinder head gasket from the cylinder head gasket chart.
   
   

 
1. Install the NEW head gasket (3) onto the engine block (5). Be sure the coolant passages align (part number should be facing up).

 
1. Install the cylinder head (2) onto the engine block (5) and install the NEW bolts (1) finger tight.
   
   

 
1. Install the intake side  (1) an securely tighten bolts (2).

 
1. Install the exhaust side  (3) an securely tighten bolts (4).
   
   
   
   

   NOTE:

   Right side shown, left side similar.

 
1. Using the tighten sequence shown, tighten the cylinder head bolts to:
   • 30 N·m (22 ft. lbs.).
   • Tighten the bolts an additional 75° turn.
   • Tighten the bolts an additional 75° turn.
   • Tighten the bolts an additional 75° turn.
   
   

 
1. Remove the bolts (2) and

 
1. Remove the bolts (4) and 
   
   

 
1. Install the bolt securing the coolant tube (2) to the cylinder head and tighten to 25 N·m (18 ft. lbs.).

 
1. Install the water pump housing assembly 
   
   

   NOTE:

   Follower and tappet assemblies must be installed in same location as when removed.

 
1. Install the followers and tappets into their original position as noted during removal.

 
1. Install the left side intake and exhaust camshafts 

 
1. Install the glow plugs and tighten to 8 N·m (71 in. lbs.).

 
1. Install the intake manifold 

 
1. Install the left side exhaust manifold 

WYMIANA PRAWEJ USZCZELKI GŁOWICY

1. Clean and inspect gasket mating surfaces 

 
1. Remove the (1).
   
   
   
   

   NOTE:

   Typical view of scooter block

 
1. Set the number one piston to top dead center (TDC).

 
1. Using the (2) and the  (1), position the dial indicator flat on the cylinder block head surface and zero the dial indicator (1).
   
   
   
   

   NOTE:

   Typical view of scooter block

 
1. Position the scooter block with dial indicator (1) onto the piston (2).
   
   

 
1. Measure the height of the piston in the location illustrated (1) and record measurement.

 
1. Measure the height of the piston in the location illustrated (2) and record measurement.

 
1. Repeat the procedure for each cylinder.

 
1. Average the 3 pistons protrusion readings to determine the required gasket thickness.
   
   

   HEAD GASKET SELECTION CHART
   	Metric	Standard
   PISTON CLEARANCE	0.130 - 0.220 mm	0.0051 - 0.0086 in.
   CYLINDER HEAD GASKET THICKNESS	0.96 mm	0.0377 in.
   GASKET IDENTIFICATION	NO HOLE
   PISTON CLEARANCE	0.221 - 0.310 mm	0.0087 - 0.0122 in.
   CYLINDER HEAD GASKET THICKNESS	1.06 mm	0.0417 in.
   GASKET IDENTIFICATION	ONE HOLE
   PISTON CLEARANCE	0.311 - 0.402 mm	0.0122 - 0.0158 in.
   CYLINDER HEAD GASKET THICKNESS	1.16 mm	0.0456 in.
   GASKET IDENTIFICATION	TWO HOLES

   
   
   
   

   NOTE:

   The above illustration shows gasket identification marks.

 
1. Select the appropriate cylinder head gasket from the cylinder head gasket chart.
   
   

 
1. Install the NEW head gasket (3) onto the engine block (5). Be sure the coolant passages align (part number should be facing up).

 
1. Install the cylinder head (2) onto the engine block (5) and install the NEW head bolts (1) finger tight.
   
   

 
1. Install the exhaust side  (1) an securely tighten bolts (2).

 
1. Install the intake side (3) an securely tighten bolts (4).
   
   

 
1. Using the tighten sequence shown, tighten the cylinder head bolts to:
   • 30 N·m (22 ft. lbs.).
   • Tighten the bolts an additional 75° turn.
   • Tighten the bolts an additional 75° turn.
   • Tighten the bolts an additional 75° turn.
   
   

 
1. Remove the bolts (4) and (4).

 
1. Remove the bolts (2) and  (1).
   
   

 
1. Install the bolt (1) securing the coolant tube (2) to the cylinder head and tighten to 25 N·m (18 ft. lbs.).

 
1. Install the water pump housing assembly 
   
   

   NOTE:

   Follower and tappet assemblies must be installed in same location as when removed.

 
1. Install the followers and tappets (2) into their original position as noted during removal.

 
1. Install the right side intake and exhaust camshafts 

 
1. Install the glow plugs and tighten to 8 N·m (71 in. lbs.).

 
1. Install the right side exhaust manifold 

 
1. Install the intake manifold 

 
1. Install the engine in the vehicle

TABELA WARTOŚCI MOMENTÓW DOKRĘCANIA

ENGINE BLOCK

CYLINDER HEAD

FRONT ENGINE

REAR ENGINE

TURBOCHARGER

ENGINE MOUNTING